Light and Thin Fabric for Comfortably Expelling Sweat

ABSTRACT

A light and thin fabric which is made by juxtapostionally knitting a hydrophilic yarn on a hydrophobic yarn by repeatedly juxtapositionally plating the hydrophilic yarn on the hydrophobic yarn to form an inner hydrophobic sublayer consisting of a plurality of inner hydrophobic loops, and an outer hydrophilic sublayer consisting of a plurality of outer hydrophilic loops, whereby the inner hydrophobic loops are adapted to be proximate or contacted with a wearer&#39;s skin or body to capillarily transfer the moisture or sweat as discharged from the wearer towards the outer hydrophilic loops; and whereby the outer hydrophilic loops are adapted to absorb the moisture or sweat from the inner hydrophobic loops to diffuse the moisture and evaporate as vapor outwardly.

BACKGROUND OF THE INVENTION

A quick drying textile (U.S. patent application Ser. No. 14/503,380), as also invented by the same applicant of this application, includes a composite fabric layer and a moisture absorbing fabric layer. The composite fabric layer includes a plurality of hydrophobic regions and a plurality of hydrophilic regions. The moisture absorbing fabric layer is combined with the composite fabric layer, whereby moisture is collected in the hydrophilic regions and is absorbed by the moisture absorbing fabric layer for vaporization.

However, this prior art may have the following drawbacks:

-   -   1. The fabric as made by jacquard knitting of the two layers,         namely the inner composite fabric layer (110) proximate to the         wearer's skin and the outer moisture absorbing fabric layer         (120) for absorbing the moisture which evaporates outwardly, may         increase the thickness and weight of the fabric product (such as         garment or sportwear), thereby causing uncomfortableness of the         wearer.     -   2. The composite fabric layer (110) comprise a plurality of         hydrophobic regions (112) and a plurality of hydrophilic regions         (114), in which an area ratio of the hydrophobic regions to the         hydrophilic regions should be designed and fabricated carefully,         to thereby increase the production complexity and cost when         designing and manufacturing such a textile.     -   3. Only the hydrophilic regions (114) in the composite fabric         layer (110) may transfer the moisture (sweat) into the outer         moisture absorbing fabric layer (120), thereby reducing the         sweat expelling speed or efficiency and still causing         unsatisfactory comfortableness for the wearer.

The present inventor has found the drawbacks of the prior art, and invented the present fabric for comfortably expelling sweat.

SUMMARY OF THE INVENTION

The object of the present invention is to provide a light and thin fabric which is made by juxtapostionally knitting a hydrophilic yarn on a hydrophobic yarn by repeatedly juxtapositionally plating the hydrophilic yarn on the hydrophobic yarn to form an inner hydrophobic sublayer consisting of a plurality of hydrophobic loops, and an outer hydrophilic sublayer consisting of a plurality of hydrophilic loops, whereby the inner hydrophobic loops are adapted to be proximate to contacted with a wearer's skin or body to capillarily transfer the moisture or sweat as discharged from the wearer towards the outer hydrophilic loops; and whereby the outer hydrophilic loops are adapted to absorb the moisture or sweat from the inner hydrophobic loops to diffuse the moisture and evaporate as vapor outwardly to make the wearer comfortable without clammy or uncomfortable feeling.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an illustration showing a fabric as made in accordance with the present invention.

FIG. 2 is a simulated illustration showing the sweat, as discharged from a wearer, being capillarity transferred and evaporated outwardly in accordance with the present invention.

DETAILED DESCRIPTION

As shown in FIG. 1, the fabric of the present invention comprises: an inner hydrophobic sublayer 1; and an outer hydrophilic sublayer 2.

A hydrophilic yarn is repeatedly juxtapositionally plated on a hydrophobic yarn to obtain the inner hydrophobic sublayer 1 consisting of a plurality of hydrophobic loops and the outer hydrophilic sublayer 2 consisting of a plurality of hydrophilic loops.

A plurality of ventilating apertures 3 are formed through the inner hydrophobic sublayer 1 and the outer hydrophilic sublayer 2 for well ventilating purpose.

The hydrophobic yarn and the hydrophilic yarn are fed into the double feeding ports of a yarn feeder of a single-knit circular knitting machine and are repeatedly knitted to plate the outer hydrophilic yarn on the inner hydrophobic yarn to juxtapositionally superimpose the outer hydrophilic yarn on the inner hydrophobic yarn to form a plurality of inner hydrophobic loops constructing an inner hydrophobic sublayer 1 and a plurality of outer hydrophilic loops constructing an outer hydrophilic sublayer 2.

The “sublayer” 1 or 2, as aforementioned, is thus defined because either the inner hydrophobic sublayer 1 or the outer hydrophilic sublayer 2 is not really a “single layer” of yarn. The inner hydrophobic yarn is served as a “ground yarn”, while the outer hydrophilic yarn is served as a “plating yarn”, both being fed into the double feeding ports of a yarn feeder of a single-knit circular knitting machine to obtain the superimposed yarn product consisting of the inner hydrophobic yarn and the outer hydrophilic yarn. Either inner yarn or outer yarn may thus be defined as a “subunit” or “sublayer” of a single layer, but rather than a single layer.

Accordingly, the present invention discloses a knitted fabric consisting of an inner sublayer 1 and an outer sublayer 2, to be totally thinner and lighter than a conventional knitted fabric which is made by a double-knit circular knitting machine to be a double-layer fabric.

Such a light and thin fabric as produced in accordance with the present invention will, of course, have the following advantages:

-   -   1. As shown in FIG. 2, the moisture M of the wearer's sweat S         will be capillarily transferred from the inner hydrophobic         sublayer 1 to the outer hydrophilic sublayer 2 to evaporate as         vapor V which will be diffused and emit to the environment to         quickly dry the fabric of the present invention. Since both         sublayers 1, 2 are so thin, the moisture M will be quickly         evaporated as vapor V by passing a short path (thin thickness)         of the fabric so soon without being condensed to be a condensate         which may blockade the outward discharge of moisture.     -   2. All loops of the inner and outer sublayers 1, 2 will form a         plurality of ventilating apertures 3, each aperture 3 playing a         role like a ventilation window or chimney to help a well         ventilation of the air, vapor or water molecules of the moisture         through the aperture 3 from the wearer's skin to the outside         surrounding or environment, thereby efficiently dissipating heat         and humid air outwardly from the wearer to make him or her more         comfortable.     -   3. The outer hydrophilic yarn is juxtapostionally superimposed         on the inner hydrophobic yarn so that the water molecules of the         sweat moisture as capillarity moving from the fiber voids in the         inner hydrophobic yarn or through the interstices among the         yarns will be instantly absorbed by the outer hydrophilic yarn,         which in turn will be quickly evaporated from the outer         hydrophilic yarn. Therefore, the moisture, as rapidly evaporated         outwardly, will not be condensed due to over saturation in the         outer yarn, and will not “re-enter” (as reverse flow) onto the         wearer's skin or body, really making him or her dry and         comfortable without clammy, cold, or “chill” feeling. The         hydrophilic yarn may be selected from polyester or nylon which         is hydrophilic inherently. A hydrophobic yarn may also be         processed to be hydrophilic by adding water absorbent agent in         dyeing or heat-set process.

The polyester yarns as used in the present invention include an inner fine hydrophobic polyester yarn having a fineness of 20˜50 deniers and an outer coarse hydrophilic polyester yarn having a fineness of 40˜200 deniers.

The knitting machine may be selected from a single-knit circular knitting machine (24 G˜42 G) for knitting the fabric consisting of the inner hydrophobic sublayer 1 and the outer hydrophilic sublayer 2 as aforementioned, but not limited in the present invention.

In order to further increase the water affinity or hydrophilic property of the hydrophilic yearn or sublayer of the present invention, the fabric after knitting the inner fine denier yarn (or the inner hydrophobic yarn) with the outer coarse yarn (or the outer hydrophilic yarn), may be further processed by adding water absorbent agent in dyeing or heat-set process to increase its hydrophilic or water absorbing property. Since the inner fine denier yarn is hydrophobic, it is uninfluenced by the wetting treatment as added with water absorbent agent. In other words, the inner fine denier yarn is not “attacked” or influenced by the wetting agent or water absorbent agent, and will remain its water repellent (hydrophobic) property.

This is very important because the fabric product may be subjected to further processing to increase the water affinity or hydrophilic property of the outer sublayer 2 without care about the inner sublayer 1 opposite to the outer sublayer 2. This is also an advantage of the present invention to enhance the economic or commercial value by reducing the production or processing cost.

The fabric by knitting the inner hydrophobic sublayer 1 and the outer hydrophilic sublayer 2 may obtain a light weight and thin thickness for the fabric product.

The area density (or weight per unit area) of a fabric made of 100% polyester is at least 110 g/m², while the area density of a fabric containing spandex and polyester yarns therein is at least 130 g/m².

The elasticity of the fabric is ranging from 30200%.

The thickness of the fabric is ranging from 0.45 mm to 0.55 mm. So, the fabric as made by the present invention is very light and thin.

The polyester yarn may be made more elastic by adding, mixing, blending with spandex yarn. In the present invention, the inner yarn may be selected from hydrophobic Tetoron or Nylon, while the outer yarn may be selected from hydrophilic Tetoron, Nylon, cotton, rayon, etc.

According to the present invention, a sportswear, shirt or garment may be made with the following steps, which are exemplified, but not limited;

-   -   1. Knitting: By using single-knit circular knitting machine to         produce the knitted fabric consisting of the inner hydrophobic         sublayer and the outer hydrophilic sublayer.     -   2. Pre-processing: Washing the fabric to remove any dirts which         may affect the dyeing quality.     -   3. Dyeing: The fabric is dyed according to the customer's         requirements.     -   4. Processed with water absorbent agent: In the dyeing bath, the         fabric is processed to be hydrophilic as treated with water         absorbent agent.     -   5. Heat setting: For stabilizing the size of the fabric, a heat         setting is performed.     -   6. Further processed with water absorbent agent: This step may         be simultaneously done when heat setting for enhancing the water         affinity, but it is optional and may not be necessary.     -   7. Cutting and/or sewing: The processed fabric is cut and sewn         to obtain a final product of garment or sportwear.

The present invention may be further modified without departing from the sprit and scope of the present invention. 

I claim:
 1. A method for making a fabric comprising: repeatedly knitting an outer hydrophilic yarn on an inner hydrophobic yarn by juxtapositionally feeding said hydrophilic yarn and said hydrophobic yarn into double feeding ports of a single-knit circular knitting machine and repeatedly plating said outer hydrophilic yarn on said inner hydrophobic yarn to juxtapositionally superimpose said outer hydrophilic yarn on said inner hydrophobic yarn to form a plurality of hydrophobic loops for constructing an inner hydrophobic sublayer adapted to be proximate or contacted with a wearer's skin or body to capillarily transfer moisture of a wearer's sweat outwardly, and form a plurality of hydrophilic loops for constructing an outer hydrophilic sublayer adapted for absorbing moisture as transferred from said inner hydrophobic sublayer to be outwardly diffused and evaporated as vapor to be released from said outer hydrophilic sublayer.
 2. A method according to claim 1, wherein said hydrophobic yarn is selected from polyester or nylon.
 3. A method according to claim 1, wherein said hydrophilic yarn is a polyester or nylon which is processed to be hydrophilic as treated with water absorbent agent.
 4. A method according to claim 1, wherein said inner hydrophobic yarn is a fine denier hydrophobic polyester yarn having a fineness of 20˜50 deniers; and said outer hydrophilic yarn is a coarse denier hydrophilic polyester yarn having a fineness of 40˜200 deniers.
 5. A method according to claim 1, wherein said fabric has an area density (or a weight per unit area) of at least 110 g/m².
 6. A method according to claim 1, wherein said fabric includes an elastic yarn, having an area density of at least 130 g/m².
 7. A method according to claim 4, wherein said fabric has an elasticity ranging from 30˜200%.
 8. A fabric comprising: an inner hydrophobic sublayer consisting of a plurality of inner hydrophobic loops adapted to be proximate or contacted with a wearer's skin or body for capillarily transferring the wearer's sweat or moisture outwardly; and an outer hydrophilic sublayer consisting of a plurality of outer hydrophilic loops, each said outer hydrophilic loop juxtapositionally superimposed on each said inner hydrophobic loop for absorbing moisture as outwardly transferred from said inner hydrophobic loop to be diffused or evaporated as vapor outwardly for quickly drying the wearer's skin or body; and each said inner hydrophobic loop formed with an inner hydrophobic yarn; each said outer hydrophilic loop formed with an outer hydrophilic yarn juxtapositionally plated by knitting on said inner hydrophobic yarn of said inner hydrophobic loop.
 9. A fabric according to claim 8, wherein said hydrophobic yarn is selected from polyester or nylon.
 10. A fabric according to claim 8, wherein said hydrophilic yarn is a polyester or nylon which is processed to be hydrophilic as treated with water absorbent agent.
 11. A fabric according to claim 8, wherein said inner hydrophobic yarn is a fine denier hydrophobic polyester yarn having a fineness of 20˜50 deniers; and said outer hydrophilic yarn is a coarse denier hydrophilic polyester yarn having a fineness of 40˜200 deniers. 